Process for manufacturing pulp, paper and paperboard products

ABSTRACT

A process for bleaching mechanical wood pulp is provided comprising subjecting the wood pulp to at least one bleaching stage with one or more bleaching agents in the presence of one or more optical brightening agent, wherein the bleaching agents are selected from the group consisting of oxidative bleaching agents other than chlorine based bleaching agents such as chlorine dioxide, elemental chlorine or a combination thereof, reductive bleaching agents or any combination of two or more thereof.

FIELD OF THE INVENTION

This invention relates to an improved method for manufacturing pulp, pulp manufactured in accordance with this process and paper and paperboard products manufactured from the pulp of this invention. More particularly, this invention relates to improvements in processes for the treatment of mechanical pulp with one or more optical brightening agents in the presence of bleaching agents other than chlorine based bleaching agents or in the presence of spent bleaching agents other than chlorine based bleaching agents.

BACKGROUND OF THE INVENTION

Mechanical pulps and processes for manufacturing mechanical pulps are known. See for example U.S. Pat. Nos. 6,527,914; 6,743,332; 5,129,987; 3,388,037; 3,467,574; 3,804,944; 3,985,674; 4,534,954; 4,676,961; 4,756,799; 4,235,665; 4,136,831; 4,012,279; 3,847,363; 3,661,320; 3,873,412 and the like.

The first step in the Mechanical pulping process is the grinding or refining of wood. The Stone Ground wood (SGW) process involves making pulp by pressing logs and chips against an abrasive rotating surface. Many years ago the grinding surface used was an actual stone. In current practice specifically designed “artificial pulp stones” are available for the grinding. A Pressurized Ground Wood (PGW) process is where the grinding operation is completely pressurized.

Another type of Mechanical pulping is Refiner Mechanical Pulp (RMP) featuring atmospheric refining with no pretreatment of the wood chips. This process is one of the main mechanical pulping operations.

Thermo Mechanical Pulping (TMP) is a Mechanical pulping process that evolved from RMP and a high temperature process known as the Apslund process. Thermo Refiner Mechanical Pulping (TRMP) is a variation in Thermo Mechanical Pulping. In this case, the chips are preheated under pressure and refining is carried out at atmospheric pressure. TMP and TRMP pulps are stronger than either SCW or RMP pulps.

The third type of pulping process is a Combination of Chemical and Mechanical pulping processes. Two types of Combination processes are ChemiMechanical Pulping and SemiMechanical Pulping. There is little difference between ChemiMechanical Pulping (CMP) and SemiChemical Mechanical Pulping (SCMP). Both processes involve pretreatment of chips with chemicals, followed by mechanical refining. Four different chemical treatments are associated with these processes. These chemical treatments are: sodium hydroxide, sodium bisulfite, sodium sulfite, and acid sulfite treatment. These processes are generally used on hardwoods. Chemical treatment weakens the fiber structure allowing fibers to rupture similarly to softwood that is mechanically pulped.

ChemiThermoMechanical Pulping (CTMP) appears to be a full evolution of all Mechanical pulping methods. It includes chemical treatment at elevated temperature steaming followed by mechanical refining. This process can produce fibrous raw materials that vary considerably in properties depending upon process conditions such as wood source, sodium sulfite concentration, pH, temperature, etc.

The foregoing list is by no means exhaustive. There are innumerable combinations and variants of the pulping processes as exemplified in The Handbook of Pulping and Papermaking, 2d ed., by Christopher J. Biermann; Acronyms for mechanical Pulp: Understanding the Alphabet Soup, TAPPI Journal (December 1987), Cooper, W and Kurdin, J. A.; Leask, R. A. and Kocurek, M. J. (Editors). Mechanical Pulping (Volume 2 of Pulp and Paper Manufacture Series) Joint Textbook Committee, 1987; and Cropp, H. V., Efficient Use of Recovered Energy is a key Mechanical Pulping Goal, Pulp & Paper (April 1991), all of which are herein incorporated by reference.

In general, while having higher yields, opacities and bulk as compared to chemical pulping processes such as Kraft and Sulfite pulping processes, mechanical pulps have a relative low ISO brightness as for example a brightness of not more than 65 ISO units for hardwood mechanical pulps and a brightness of nor more than 60 ISO brightness units for softwood mechanical pulps because of the substantial amounts of retained lignin. To enhance the brightness of mechanical pulp, such pulp has been subjected to one or more subsequent bleaching stages. For example, mechanical pulp resulting from a ChemiThermoMechanical Pulping (CTMP) process can be subjected to one or more subsequent bleaching stages to form Bleached Chemical Thermomechanical Pulp (BCTMP).

Bleaching is a term applied to a semi-chemical or chemical step in a in which the mechanical pulp is treated with an active bleaching agent, such as chlorine, chlorine dioxide, ozone, oxygen, hydrogen peroxide, peroxy acids, enzymes, or a mixture thereof, at a controlled time, temperature, and pH. The desired outcome of these reactions is to brighten the mechanical pulp to ever-higher levels of brightness (the Technical Association of the Pulp & Paper Industry (“TAPPI”) or the International Organization for Standardization (“ISO”)). Brightness levels can be increased to some extent. For example, the ISO brightness of softwood mechanical pulps can be increased to about 75 ISO with one conventional peroxide bleaching stage and about 80 ISO with two conventional peroxide bleaching stages and the ISO brightness of hardwood mechanical pulps can be increased to about 80 ISO with one peroxide bleaching stage and about 85 ISO with two conventional peroxide bleaching stages. Widespread consumer preference for a brighter, whiter pulp drives manufacturers to pursue ever more aggressive bleaching strategies. However, while brightness levels are increased somewhat, other properties of the mechanical pulp are adversely impacted such as bulk and opacity which increases with increasing bleaching. While highly bleached pulps are “whiter” than their less-bleached cousins, they are still yellow-white in color. A yellow-white product is undesirable. Countless studies suggest that consumers clearly favor a blue-white over a yellow-white color. The former is perceived to be whiter, i.e., “fresh”, “new” and “clean”, while the latter is judged to be “old”, “faded”, and “dirty”.

Further optical enhancement in brightness is usually accomplished by the addition of tinting colorants, fillers, and/or Fluorescent whitening agents (FWA) or optical brightening agents (OBA). usually added during the stage during which the pulp is mixed with A optical brightening agents and processes for enhancing the brightness pulp or paper fibers are described in U.S. Pat. Nos. 5,482,514; 6,893,473; 6,723,846; 6,890,454; 6,426,382; 4,169,810; 5,902,454; and U.S. Pat. Application Publication Nos. US 2004/014910 and US 2003/0013628.

SUMMARY OF THE INVENTION

One aspect of this invention relates to an improved process for treating mechanical pulp comprising treating the pulp with one or more optical brightening agents in the presence of bleaching agents other than chlorine based bleaching agents or in the presence of spent bleaching agents other than chlorine based bleaching agents. The treatment is preferably carried out during a bleaching stage. The bleaching agents are selected from the group consisting of oxidative bleaching agents other than chlorine based bleaching agents such as chlorine dioxide, elemental chlorine or a combination thereof, reductive bleaching agents or any combination of two or more thereof. The process of the present invention provides for one or more advantages over prior processes for brightening bleached and/or unbleached mechanical pulps. For example, advantages of some of the embodiments of the process of this invention include mechanical pulp having high ISO brightness levels and/or CIE Whiteness levels. In certain embodiments, lower amounts of bleach chemicals can be used to attain ISO brightness levels and/or CIE Whiteness levels as compared to conventional processes. In still other embodiments of the invention, high ISO brightness levels and/or CIE Whiteness levels can be obtained without adversely impacting mechanical pulp bulk and/or opacity unduly. Some embodiments of this invention may exhibit one of the aforementioned advantages while other preferred embodiments may exhibit two or more of the foregoing advantages in any combination.

Another aspect of this invention relates to brightened mechanical pulp having a brightness equal to or greater than 90 ISO and pulp mixtures comprising such mechanical pulp. Still another aspect of this invention relates to bleached mechanical pulp having brightness increased by from about 5 to about 10 ISO units greater than brightness levels of conventional bleached mechanical pulps while not adversely impact the bulk or opacity properties of the pulp to an undue extent.

Still another aspect of this invention relates to an improved process for forming bleached mechanical pulp of the type comprising:

(a) a mechanical refining stage wherein wood chips are mechanically refined to form mechanical refined wood pulp; and

(b) a bleaching stage wherein said mechanical refined wood pulp is bleached in one or more bleaching stages to form a bleached mechanical refined wood pulp;

the improvement comprising bleaching the mechanical refined wood pulp with one or more bleaching agents in the presence of one or more optical brightening agent, said bleaching agents selected from the group consisting of oxidative bleaching agents other than chlorine based bleaching agents such as chlorine dioxide, elemental chlorine or a combination thereof, reductive bleaching agents or any combination of two or more thereof.

Yet another aspect of this invention relates to an improved pulping and paper making process of the type comprising:

(a) a mechanical refining stage wherein wood chips are mechanically refined to form mechanical refined wood pulp,

(b) a bleaching stage wherein said mechanically refined wood pulp is bleached in one or more bleaching stages to form bleached mechanical refined aspen wood pulp,

(c) a furnish forming stage wherein an aqueous paper making stock furnish comprising said bleached mechanical refined wood pulp is formed;

(d) a furnish depositing stage wherein said furnish is deposited on a forming wire of a paper making machine to form a wet paper web; and

(e) a wet paper web drying stage wherein said wet paper web to form a first dried paper web,

the improvement comprising bleaching the mechanical refined wood pulp with one or more bleaching agents in the presence of one or more optical brightening agents, said bleaching agents selected from the group consisting of oxidative bleaching agents other than chlorine based bleaching agents such as chlorine dioxide, elemental chlorine or a combination thereof, reductive bleaching agents or any combination of two or more thereof.

Still another aspect of this invention relates to the paper web comprising bleached mechanical pulp having an ISO brightness equal to or greater than about 90, said pulp preferably having a bulk equal to or greater than about 2 cm̂3/g and an opacity equal to or greater than about 79% and pulp mixtures comprising such mechanical pulp.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIGS. 1 to 3 are graphs, illustrating improvement in the ISO brightness, CIE Whiteness and yellow shade b* value, when the invention was practice with disulfonated stilbene based OBA obtained from Clariant under the tradename Leucophor AP and was applied to Aspen BCTMP which had gone through the first hydrogen peroxide bleaching stage to the first stage brightness targets of 73 ISO, 77 ISO and 82 ISO.

FIGS. 4 to 6 are graphs, illustrating improvement in ISO brightness, CIE Whiteness and yellow shade b* value, when the invention was applied to Aspen BCTMP which was bleached in the first hydrogen peroxide stage to the first stage brightness target of 82 ISO and when the invention was practiced using Leucophor AP or tetra sulfo stilbene based OBA obtained from Clariant under the tradename Leucophor T-100.

FIGS. 7 to 9 are graphs, illustrating improvement in ISO brightness, CIE Whiteness and yellow shade b* value, when the invention was applied to Aspen BCTMP which was bleached in the first hydrogen peroxide stage to the first stage brightness target of 77 ISO and when the invention was practice with either a simultaneous mixing of Leucophor AP with all bleaching chemicals at the beginning of the peroxide bleaching or with a sequential mixing of OBA with pulp at the end of the peroxide bleaching stage but before the pulp washing.

FIGS. 10 to 12 are comparative graphs, showing comparative improvement in ISO brightness, CIE Whiteness and yellow shade b* value, when the prior art of mixing OBA with pulp was practiced on an 82 ISO Aspen BCTMP and when either Leucophor AP or Leucophor T-100 was used.

FIGS. 13 to 15 are comparative graphs, similar to FIGS. 10-12 but for the case of 77 ISO Aspen BCTMP.

FIGS. 16 to 18 are graphs, illustrating improvement in ISO brightness, CIE Whiteness and yellow shade b* value, when the invention was applied to 82 ISO Aspen BCTMP and when the reaction time of the invention was varied from 1 hour to 4 hours.

FIGS. 19 to 24 are photomicrographs pulp fibers treated with OBA in accordance with the process of this invention and pulp fibers treated with OBA in the absence of active and spent bleaching chemicals.

DETAILED DESCRIPTION OF THE INVENTION

The process of this invention is an improvement in those processes of treating mechanical pulp with optical brightening agents to increase pulp brightness and/or whiteness. In the present invention, pulp is treated with one or more optical brightening agents in the presence of one or more bleaching agent selected from the group consisting of bleaching agents other than chlorine based bleaching agents. In the preferred embodiments of this invention, the bleaching agents may be active in which case the optical brightening agent can be added during one or more bleaching stages with one or more suitable bleaching agents. Order and point of addition of the optical brightening agent and the bleaching agent to the treating mixture are not critical. For example, the optical brightening agent can be added prior to the addition of bleaching agent and/or other bleaching chemicals, with one or more of the bleaching agent and/or other bleaching chemicals, after the initial addition of the bleaching agent and/or other bleaching chemicals, at any time during bleaching and at any time after the completion of the bleaching process in the presence of the spent bleaching agent. The optical brightening agent is preferably added in admixture with the bleaching agent and/or one or more other bleaching chemicals.

The plant source of mechanical pulp for use in this invention is not critical and may be any fibrous plant which can be subjected to mechanical pulping. Examples of such fibrous plants are trees, including hardwood fibrous trees such as aspen, eucalyptus, maple, birch, walnut, acacia and softwood fibrous trees such as spruce, pine, cedar, including mixtures thereof. In certain embodiments, at least a portion of the pulp fibers may be provided from non-woody herbaceous plants including, but not limited to, kenaf, hemp, jute, flax, sisal, or abaca although legal restrictions and other considerations may make the utilization of hemp and other fiber sources impractical or impossible. The source of mechanical pulp for use in the practice of this invention is preferably hardwood and softwood fibrous trees, more preferably Eucalyptus, Spruce and Aspen and is most preferably Aspen and Spruce.

The mechanical pulp used in the process of this invention can obtained by subjecting the fibrous plant to any mechanical pulping process in which the fibrous plant is mechanically triturating wood into its fibers for the purpose of making pulp. There are many variants of mechanical pulping which can be used make the mechanical pulp used in the process of this invention. Illustrative of such mechanical pulping processes are those described in The Handbook of Pulping and Papermaking, 2d ed., by Christopher J. Biermann; Acronyms for mechanical Pulp: Understanding the Alphabet Soup; TAPPI Journal (December 1987), Cooper, W and Kurdin, J. A.; Leask, R. A. and Kocurek, M. J. (Editors) Mechanical Pulping (Volume 2 of Pulp and Paper Manufacture Series) Joint Textbook Committee, 1987; and Cropp, H. V., Efficient Use of Recovered Energy is a key Mechanical Pulping Goal, Pulp & Paper (April 1991), “Handbook For Pulp & Paper Technologies”, 2^(nd) Edition, G. A. Smook, Angus Wilde Publications (1992) and references cited therein, all of which are herein incorporated by reference. Such methods include stone grinding (SG), pressurized stone grinding (PSG), refiner mechanical pulping (RMP), thermo mechanical pulping (TMP), chemi-thermomechanical pulping (CTMP), bleached chemi-thermomechanical pulping (BCTMP) and the like. Preferred for use in the practice of this invention is mechanical pulp made by thermo mechanical pulping (TMP), chemi-thermomechanical pulping (CTMP) and bleached chemi-thermomechanical pulping (BCTMP) processes. More preferably the pulp is made by chemi-thermomechanical pulping (CTMP) and bleached chemi-thermomechanical pulping (BCTMP) processes and most preferably by bleached chemi-thermomechanical pulping (BCTMP) processes.

The bleaching consistency may vary widely and any consistency that provides the desired increase in pulp brightness may be used. The mechanical pulp may be bleached under low consistency conditions (i.e. from about 3% to about 6% based on the total weight of the mixture of pulp and bleaching chemicals), medium consistency conditions (i.e. from about 8% to about 14% based on the total weight of the mixture of pulp and bleaching chemicals) or high consistency conditions (i.e. from about 20% to about 30% based on the total weight of the mixture of pulp and bleaching chemicals). The consistency is preferably 10%, more preferably 14% and most preferably 25%. The consistency may be 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 222, 23, 24, 25, 26, 27, 28, 29, and 30%, including and all ranges and subranges therein.

Optical brightening agents (“OBAs”) used in the practice of the process of this invention may vary widely and any conventional OBA used or which can be used to brighten mechanical or Kraft pulp can be used in the conduct of the process of this invention. Optical brighteners are dye-like fluorescent compounds are substances that absorb light in the invisible ultraviolet region of the spectrum and reemit it in the visible portion of the spectrum, particularly in the blue to blue violet wavelengths. This provides added brightness and can offset the natural yellow cast of a substrate such as paper. Optical brighteners used in the present invention may vary widely and any suitable optical brightener may be used. An overview of such brighteners is to be found, for example, in Ullmann's Encyclopedia of Industrial Chemistry, Sixth Edition, 2000 Electronic Release, OPTICAL BRIGHTENERS—Chemistry of Technical Products which is hereby incorporated, in its entirety, herein by reference. Other useful optical brighteners are described in U.S. Pat. Nos. 5,902,454; 6,723,846; 6,890,454; 5,482,514; 6,893,473; 6,723,846; 6,890,454; 6,426,382; 4,169,810; and 5,902,454 and references cited therein which are all incorporated by reference. Still other useful optical brighteners are described in; and U.S. Pat. Application Publication Nos. US 2004/014910 and US 2003/0013628; and WO 96/00221 and references cited therein which are all incorporated by reference. Illustrative of useful optical brighteners are 4,4′-bis-(triazinylamino)-stilbene-2,2′-disulfonic acids, 4,4′-bis-(triazol-2-yl)stilbene-2,2′-disulfonic acids, 4,4′-dibenzofuranyl-biphenyls, 4,4′-(diphenyl)-stilbenes, 4,4′-distyryl-biphenyls, 4-phenyl-4′-benzoxazolyl-stilbenes, stilbenzyl-naphthotriazoles, 4-styryl-stilbenes, bis-(benzoxazol-2-yl) derivatives, bis-(benzimidazol-2-yl) derivatives, coumarins, pyrazolines, naphthalimides, triazinyl-pyrenes, 2-styryl-benzoxazole or -naphthoxazoles, benzimidazole-benzofurans or oxanilides.

Most commercially available optical brightening agents are based on stilbene, coumarin and pyrazoline chemistries and these are preferred for use in the practice of this invention. More preferred optical brighteners for use in the practice of this invention are optical brighteners typically used in the paper industry based on stilbene chemistry such as 1,3,5-triazinyl derivatives of 4,4′-diaminostilbene-2,2′-disulfonic acid and salts thereof, which may carry additional sulfo groups, as for example at the 2, 4 and/or 6 positions. Most preferred are the commercially available stilbene derivatives as for example those commercially available from Ciba Geigy under the tradename “Tinopal”, from Clariant under the tradename “Leucophor”, from Lanxess under the tradename “Blankophor”, and from 3V under the tradename “Optiblanc” such as disulfonate, tetrasulfonate and hexasulfonate stilbene based optical brightening agents. Of these most preferred commercial optical brightening agents, the commercially available disulfonate and tetra sulfonate stilbene based optical brightening agents are more preferred and the commercially available disulfonate stilbene based optical brightening agents is most preferred.

The amount of optical brightener used in the practice of the process of this invention can vary widely and any amount sufficient to provide the desired degree of brightness can be used. In general, the lesser the amount of optical brightener employed the less the enhancement in ISO brightness of the final pulp product. Conversely, the greater the amount of optical brightener used the greater the enhancement in pulp brightness except that while we do not wish to be bound by any theory, it is believe that at some point the addition of more optical brightener will not have any further appreciable impact on pulp brightness and may even result in a decrease in pulp brightness. The amount of optical brightener used is usually at least about 0.1% based on the dry weight of the pulp. Preferably the amount of optical brightener is from about 0.1% to about 2%, more preferably from about 0.2% to about 1.5% and most preferably from about 0.25% to about 1% on the aforementioned basis. The amount of optical brightener may be 0.1, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, 0.5, 0.55, 0.6, 0.7, 0.75, 0.8, 0.9, 1.0, 1.25, 1.5, 1.75, and 2.0 wt % based upon the total dry weight of the fibers, including and all ranges and subranges therein.

Any oxidative bleaching other than a chlorine based bleaching agent can be used in the practice of this invention and any reductive bleaching agent can be used. Suitable bleaching agents are described in “The Bleaching of Pulp” 3^(rd) Ed. RP. Singh, TAPPI PRESS, Atlanta, Ga. 1979. Illustrative of suitable oxidative bleaching agents are oxygen, peroxides and per-oxy acids or acid derivatives of hydrogen peroxide such as peroxymono sulfuric acid and peroxyacetic acid, dimethyl dioxirane. However, besides pulp brightness improvement, the use of these peroxy acids on mechanical pulps could result in undesirable side effects such as yield loss through dissolution and removal or lignin and some decomposition of OBA chemicals. Such undesirable effects can be minimized through delaying the mixing OBA with pulp toward the later part of the bleaching stage, after most of bleaching chemicals was consumed. Illustrative reducing bleaching agents are sodium hydrosulfite, sodium bisulfite and zinc hydrosulfite. To minimize the lignin removal and yield loss and undesirable decomposition of OBA, peroxides are therefore the most preferred bleaching agents.

The amount of bleaching agent used in the practice of the process of this invention can vary widely and any amount sufficient to provide the desired degree of brightness can be used. In general, the lesser the amount of bleaching agent employed the less the enhancement in ISO brightness of the final pulp product. Conversely, the greater the amount of bleaching agent used the greater the enhancement in pulp brightness except that the greater the amount of bleaching agent employed the greater the reduction in the bulk and porosity of the bleached mechanical pulp product. The amount of bleaching agent used is usually at least about 0.5% based on the dry weight of the pulp. Preferably the amount of bleaching agent is from about 0.5% to about 10%, more preferably from about 1% to about 9% and most preferably from about 1.5% to about 6% on the aforementioned basis, including and all ranges and subranges therein. The amount of bleaching agent may be 0.5, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5, 8.0, 8.5, 9.0, 9.5, and 10.0 wt %, including any and all ranges and subranges therein.

In the most preferred embodiments of the invention when hydrogen peroxide is the bleaching agent, the amount of hydrogen peroxide in the bleaching liquor is preferably from about 10 to about 200 pounds per ton of pulp on a dry basis. The hydrogen peroxide is conventionally obtained from suppliers as a mixture of 60% water and 40% hydrogen peroxide on a weight basis, but other proportions of water and hydrogen peroxide can be used, provided they are equivalent to 10 to 200 pounds of a 60:40 mixture. An acceptable ratio of alkalinity to hydrogen peroxide is about 0.25 to about 3 on a weight basis of the 60:40 mixtures. These amounts of hydrogen peroxide can be applied to the methods of brightening mechanical pulps according to the present invention.

The bleaching liquor can also contain various optional components which stabilize the bleaching agent under bleaching conditions and do so in the preferred embodiments of the invention. The particular stabilizer used will depend on the bleaching agent employed and any conventional stabilizer can be used in the practice of the invention. For example useful stabilizers include but are not limited to silicates such as sodium silicate and chelating agents, such as, but not limited to aminopolycarboxylic acids (APCA), ethylenediaminetetraacetic acid (EDTA), diethylene triamine pentaacetic acid (DTPA), nitrilotriacetic acid (NTA), phosphonic acids, ethylenediaminetetramethylene-phosphonic acid (EDTMP), diethylenetriaminepentamethylenephosphonic acid (DTPMP), nitrilotrimethylenephosphonic acid (NTMP), polycarboxylic acids, gluconates, citrates, polyacrylates, and polyaspartates or any combination thereof. Mixtures of thermodynamic and kinetic controlling chelating agents (e.g. citrates, keto acids, gluconates, heptagluconates, phosphates, and phosphonates) also work well in reducing the content of free heavy metal ions in the paper to acceptable levels. Kinetic controlling chelating agents are those which do not form a stable, isolable, complex with a heavy metal ion. In the most preferred embodiments of the invention where hydrogen peroxide is the bleaching agent silicates preferably sodium silicate and a chelating agent preferably diethylene triamine pentaacetic acid (DTPA) are used. Reference is made to the following articles for detailed descriptions of the chemical activity provided by stabilizers such as chelating agents and silicates: Pulp Bleaching: Principles and Practice, by Carlton W. Dence and Douglas W. Reeve, Tappi Press, Technology Park, PO Box 105113, Atlanta, Ga. (1996) and V. N. Gupta, Pulp Paper Mag. Can., 71 (18), T391-399 (1970, which are herein incorporated by reference.

Any amount of these optional components can be used for the desired effect and usually conventional amounts are employed. For example, each stabilizer can be present in an amount of up to about 10% by weight. In one embodiment, the optional component, stabilizer or mixtures thereof may be present in an amount that is up to about 10 wt %, preferably up to about 8 wt %, more preferably up to about 6 wt % based upon the dry weight of the fibers, including and all ranges and subranges therein.

In addition to stabilizers such as silicates and chelating agents, the bleaching liquor can also include bleaching aids in amounts of up to 10% by weight. Bleaching aids further enhance the bleaching activity. Bleaching aids include adjuvants such as Chip Aid® and HP Booster supplied from Constant Labs of Montreal, Canada. Adjuvants such as chelating agents and bleaching aids can be applied to the method of brightening mechanical pulps according to the invention.

The composition of the bleaching liquor has been described as a mixture. However, it should be readily apparent that the components of the bleach liquor can be added separately or in mixtures of any combination in any order.

Bleaching times will vary widely and conventional bleaching times may be used. As is known in the art, bleaching times will usually depend upon available process equipment, production rates, temperatures, pulp, bleach chemicals, end pH, and other bleaching conditions. Usually, bleaching times will be at least about 20 minutes. Bleaching times are preferably from about 30 minutes to about 10 hours, and are more preferably from about 60 minutes to about 8 hours and most preferably from about 90 minutes to about 6 hours. Bleaching or contacting times include 60 minutes, 90 minutes, 2 hours, 3, hours, 4 hours, 5 hours, 6 hours, 7 hours, 8 hours, 9 hours, and 10 hours, including any and all ranges and subranges therein.

Similarly, bleaching temperatures employed in the critical bleaching stage may vary widely and temperatures employed in conventional bleaching stages may be used. For example, useful temperatures can be as low as about 25° C. or lower and as high as about 100° C. or higher. In the process of this invention, the bleaching temperature is usually from about 25° C. to about 120° C., preferably from about 40° C. to about 100° C., more preferably from about 60° C. to about 90° C. and most preferably from about 70° C. to about 80° C.

The end pH of the bleaching stage may vary widely and can be any value which is normally obtained in conventional bleaching stages with hydrogen based bleaching agents. For example, the end pH can be as high as about 11 and higher and as low as about 7 and lower. In the preferred embodiments of the invention, the end pH is equal to or greater than about 7.0, in the more preferred embodiments of the invention is from about 7 to about 10, and in the most preferred embodiments of the invention is from about 8 to about 9.

The beginning pH of the bleaching stage may vary widely and can be any value which is normally obtained in conventional bleaching stages with chlorine-based bleaching agents. For example, the beginning pH can be as high as about 12 and as low as about 9. In the preferred embodiments of the invention, the beginning pH is equal to or higher than about 10 and in the more preferred embodiments of the invention is from about 10 to about 11.

Bleaching pH can be controlled using materials used in conventional bleaching processes in conventional amounts. For example, where the bleaching agent is peroxide pH can be controlled through use of an alkali buffer such as soda ash, magnesium hydroxide or the like, or by the addition of an organic or inorganic base such as sodium hydroxide, ammonia, ammonium hydroxide, potassium hydroxide or the like.

In this invention, the mechanical pulp can be bleached in a single bleaching stage or can be bleached in more than one bleaching stage. In each instance, the brightness of the pulp will be greater than the brightness of the mechanical pulp bleached under the same conditions except that no optical brightener is added to the bleaching stage. While pulp brightness increases with the number of bleaching stages, other important properties of the pulp such as bulk and opacity decrease. Accordingly, the number of bleaching stages can be varied to optimize the brightness, bulk and opacity properties of the bleached pulp consistent with the desire use of the pulp.

The types of bleaching sequences and the number and type of bleaching stages comprising the sequences may vary widely provided that the essential bleaching stage with one or more optical brighteners and one or more oxidative or reductive bleaching agents other than a chlorine based bleaching agent is present. In the preferred embodiment of this invention, the bleaching process of this invention comprises one or two stages.

Certain bleached mechanical pulps of this invention exhibit superior ISO brightness as determined by the standard TAPPI T452 om-02 test method, especially as compared to mechanical pulp bleached under the same conditions but excluding the optical brightener. In these embodiments, the incremental increase in the ISO brightness of the pulp, as a result of optical brightener addition is usually at least about 2 ISO points. The incremental brightness increase of the pulp is preferably at least about 4 ISO points, more preferably from about 6 ISO points to about 8 ISO points and most preferably from about 9 ISO points to about 11 ISO points.

Other bleached mechanical pulps of this invention exhibit relatively high ISO brightness and because of the enhanced bleaching efficiency also exhibit relatively high bulk as determined by the standard TAPPI T411 and T452 om-02 testing methods and opacity as determined by the standard TAPPI T519 om-02 test method. In these embodiments, the ISO brightness of the pulp is usually at least about 80 ISO, the bulk is usually equal to or greater than about 1.8 cm̂3/g and the opacity is usually equal to or greater than about 78%. The ISO brightness of the pulp is preferably at least about 85 ISO, the bulk is preferably equal to or greater than about 2.2 cm̂3/g and the opacity is preferably equal to or greater than about 80%. In the more preferred embodiments, the ISO brightness of the pulp is at least about 90 ISO, the bulk is equal to or greater than about 2.0 cm̂3/g and the opacity is equal to or greater than about 78%, and in the most preferred embodiments, the ISO brightness of the pulp is at least about 95 ISO, the bulk is equal to or greater than about 1.9 cm̂3/g and the opacity is equal to or greater than about 78%.

The present invention relates in part, to a fiber:OBA complex in which the affinity of the OBA added to the fiber according to present invention is preferably greater than that when the OBA is added to the fiber conventionally. When the OBA is added to the fiber according to the method of the present invention, there is 30 to 60% reduction in the OBA required to be added than that of conventional methods and addition points. The reduction may be 30, 31, 32, 33, 34, 35, 40, 45, 50, 55, 56, 57, 58, 59, and 60% compared to that required in conventional methods and addition points, including any and all ranges and subranges therein.

In addition, the present invention preferably provides increased the penetration of OBA into the cell wall of a mechanical pulp fiber which in these preferred embodiments of the invention is believed to increase affinity of the OBA to the mechanical pulp fiber. Because the OBA has increased affinity to the mechanical pulp fiber overall in the present inventive mechanical pulps and paper substrates made therefrom compared to conventional pulp, it will take a longer period of time for the OBA to be extracted from the mechanical pulp pulp:OBA complex of the present invention (mechanical pulp and/or paper) at a given time period and temperature for a given solvent. The amount of OBA present within the cell wall of mechanical pulp fiber may be measured, for example, by microscopy, more specifically fluorescent microscopy and the affinity of the OBA to the mechanical pulp fiber may be measured by extraction methods using any solvent, preferably water, at any temperature. Preferably, there is a greater amount of OBA that has penetrated the cell wall of a mechanical pulp fiber treated according to the present invention than that of mechanical pulp fibers treated with OBA using conventional methods after bleaching. More preferably, the amount of OBA present within the cell wall of the mechanical pulp fiber is increased by at least 1% more than the amount of OBA present within the cell wall of mechanical pulp fiber that was treated in conventional methods. However, it is more preferred that the amount of OBA present within the cell wall of the mechanical pulp fiber is increased by at least 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 100, 200, 300, 500, and 1000% than the amount of OBA present within the cell wall of fiber that was treated in conventional methods, including any and all ranges and subranges therein.

More preferably, the amount of the cell wall of the mechanical pulp fiber penetrated by the OBA is at least 1%. However, it is more preferred that the amount of the cell wall of the mechanical pulp fiber penetrated by the OBA is at least 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 100 including any and all ranges and subranges therein.

In one embodiment of the present invention, mixtures of mechanical and chemical fibers may be treated according to the present invention. Examples of such chemical fibers include Kraft Fibers from any of the above-mentioned sources, preferably from either hardwood or softwood species. The mechanical and/or chemical fibers may have already undergone bleaching such as D1 and/or D2 bleaching stages (where above-mentioned chlorine-based bleaching agents may be utilized) prior to mixing. In such an embodiment, after washing each of the mechanical and/or chemical fibers, the resultant mixture may then be treated according to the present invention.

When mixtures of mechanical and chemical fibers are treated according to the present invention, the mechanical fiber may have any Canadian standard freeness, but preferably not less than 200. The Canadian Standard Freeness of the mechanical fiber may be not less than 200, 225, 250, 275 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420, 430, 440, 450, 460, 470, 480, 490, 500, 510, 520, 530, 540, 550, 600, and 700 csf, including any and all ranges and subranges therein

When mixtures of mechanical and chemical fibers are treated according to the present invention, the mechanical fiber may have any % shive content, preferably not more than 0.5%, more preferably not more than 2%. The shive content may be measured, for example, using a Shive ratio analyzer such as those in exemplified in U.S. Pat. No. 4,225,385, which is hereby incorporated in its entirety by reference. The % shive content may be less than 0.5, 0.4, 0.3, 0.2, 0.1, 0.075, 0.05, 0.025, 0.01, and 0.005, including any and all ranges and subranges therein.

When mixtures of mechanical and chemical fibers are treated according to the present invention, the amount of chemical fibers in the mixture may be any amount, preferably from 20 to 90 wt % based upon the total dry weight of the fibers. The amount of chemical fibers may be greater than 30, preferably greater than 40, more preferably greater than or equal to 50 wt % based upon the total dry weight of the fibers. The amount of chemical fibers may be not more than 95, preferably not more than 90, more preferably nor more than 85, and most preferably not more than 80 wt % based upon the total dry weight of the fibers. The amount of chemical fibers may include 20, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85 and 90 wt % based upon the total dry weight of the fibers, including any and all ranges and subranges therein.

When mixtures of mechanical and chemical fibers are treated according to the present invention, the amount of mechanical fibers in the mixture may be any amount, preferably from 10 to 80 wt % based upon the total dry weight of the fibers. The amount of mechanical fibers may be greater than 30, preferably greater than 40, more preferably greater than or equal to 50 wt % based upon the total dry weight of the fibers. The amount of mechanical fibers may be not more than 75, preferably not more than 70, more preferably nor more than 65, and most preferably not more than 60 wt % based upon the total dry weight of the fibers. The amount of mechanical fibers may include 10, 20, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, and 80 wt % based upon the total dry weight of the fibers, including any and all ranges and subranges therein.

When mixtures of mechanical and chemical fibers are treated according to the present invention, the amounts of bleaching agent, optical brightening agent, optional component, stabilizer, etc are the same as that mentioned above. Further, the temperature, consistency, contact time, and pH may be the same as mentioned above as well.

In addition the treated mixed pulp or mechanical and chemical fibers may have enhanced ISO brightness and enhanced bulk as well. The ISO brightness of the pulp may be any of the above-mentioned ISO Brightness. The ISO brightness may be any, preferably greater than 85, more preferably greater than 87, most preferably greater than 90. The ISO brightness may be 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, and 99 or greater, including any and all ranges and subranges therein. In addition, the mixed pulp may have an increased ISO Brightness of at least 20 ISO points, preferably at least 30 ISO points, more preferably at least 35 ISO points, most preferably at least 40 ISO points. The increased Brightness may be 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, and about 40 or greater from the ISO brightness of the beginning pulp mixture, including any and all ranges and subranges therein.

The resultant pulps of this invention may be combined with any other pulps. In one embodiment, the pulp of the present invention may be added to chemical pulps such as Kraft (hardwood or softwood or any of the above-mentioned fiber sources). Examples of such additional pulps that may be combined with the mechanical pulp of the present invention include, but is not limited to those found in United States Patent Publication Number 2006-0185808 and U.S. patent application Ser. No. 11/445,809 entitled “Pulp and Paper Having Increased Brightness” filed Jun. 2, 2006, which are hereby incorporated, in their entirety, herein by reference.

The pulps of this invention have a wide variety of uses for which pulps can be used. For example, the pulp can be used to make fluff pulp that can be in the fabrication of absorbent articles such as diapers, feminine hygiene and adult incontinence products, wipes, towels and the like. Illustrative of such absorbent products are those described in United States Published Patent Application 2007-0000627, as well as U.S. Pat. Nos. 5,766,159 and 6,063,982, which are hereby incorporated, in their entirety, herein by reference.

The pulp of this invention can also be used in the manufacture of paper and packaging products such as printing, writing, publication and cover papers and paperboard products.

Illustrative of these products and processes for their manufacture are those described in U.S. Pat. Nos. 5,902,454 and 6,464,832, which are hereby incorporated, in their entirety, herein by reference.

For example, in the paper or paperboard making process, the bleached pulp of this invention or pulp mixtures comprising the bleached pulp of this invention is formulated into an aqueous paper making stock furnish which also comprises one of more additives which impart or enhance specific sheet properties or which control other process parameters. Illustrative of such additives is alum which is used to control pH, fix additives onto pulp fibers and improve retention of the pulp fibers on the paper making machine. Other aluminum based chemicals which may be added to the furnish are sodium aluminate, poly aluminum silicate sulfate and poly aluminum chloride. Other wet end chemicals which may be included in the paper making stock furnish for conventional purposes are acid and bases, sizing agents, dry-strength resins, wet strength resins, fillers, coloring materials, retention aids, fiber flocculants, defoamers, drainage aids, optical brighteners, pitch control chemicals, slimicides, biocides, specialty chemicals such as corrosion inhibitors, flame proofing and anti-tarnish chemicals, and the like. Methods and procedures for formulating mechanical bleached pulp, aluminum based wet end chemicals and other optional wet end chemicals are well known in the art and will not be described in any great detail. See for example, Pulp and Paper Manufacture, Pulp and Paper Chemistry and Pulp Bleaching, and Handbook For Pulp & Paper Technologies, supra.

The aqueous paper making stock furnish comprising the bleached mechanical pulp and the aluminum based compounds is deposited onto the forming wire of a conventional paper making machine to form a wet deposited web of paper or paperboard and the wet deposited web of paper or paperboard is dried to form a dried web of paper or paperboard. Paper making machines and the use of same to make paper are well known in the art and will not be described in any great detail. See for example, Pulp and Paper Chemistry and Handbook For Pulp & Paper Technologies, supra. By way of example, the aqueous paper making stock furnish containing pulp, aluminum based and other optional additives and usually having a consistency of from about 0.3% to about 1% is deposited from the head box of a suitable paper making machine as for example a twin or single wire Fourdrinier machine. The deposited paper making stock furnish is dewatered by vacuum in the forming section. The dewatered furnish is conveyed from the forming section to the press section on specially-constructed felts through a series of roll press nips which removes water and consolidates the wet web of paper and thereafter to the dryer section where the wet web of paper is dried to form the dried web of paper of this invention. After drying, the dried web of paper may be optionally subjected to several dry end operations such as and various surface treatments such as coating, and sizing and calendering.

The paper and/or paperboard manufactured in accordance with this invention can be used for conventional purposes. For example, the paper is useful as printing paper, publication paper, newsprint and the like.

In one embodiment, the paper and/or paperboard containing the pulp of the present invention has any of the above-mentioned brightness. Further, the paper or paperboard may have enhanced surface strength and acceptable internal bond and hygroexpansivity, such as that described in U.S. patent application Ser. No. 11/655,004, filed Jan. 17, 2007, and entitled “PAPER SUBSTRATES CONTAINING HIGH SURFACE SIZING AND LOW INTERNAL SIZING AND HAVING HIGH DIMENSIONAL STABILITY”, which is hereby incorporated, in its entirety, herein by reference. In addition, the paper may contain bulking agents such as expandable microspheres as well as those mentioned in United States Patent Application Publications 2004-0065423 and 2007-0044929, as well as U.S. Provisional Patent Application 60/926,214, filed Apr. 25, 2007 and entitled “EXPANDABLE MICROSPHERES AND METHODS OF MAKING AND USING THE SAME”, which are all hereby incorporated, in their entirety, herein by reference.

The present invention is described in more detail by referring to the following examples and comparative examples which are intended to more practically illustrate the invention and not to be a limitation thereon.

EXAMPLES 1A TO 10D AND COMPARATIVE EXAMPLES C1 to C34

A series of experiments were carried out to demonstrate the invention in detail. One purpose of these experiments is to demonstrate the effect of treatment time, temperature, consistency and chemical additives (OBA, H₂O₂, Na₂SiO₃, DTPA) on the ISO brightness and the CIE Whiteness of the treated Aspen BCTMP pulp. In these experiments, distill/deionize water was added to the starting Aspen BCTMP pulp having a starting ISO brightness and CIE whiteness to form a slurry having the desired pulp consistency target. Bleach chemical solutions containing the desired amounts of H₂O₂, NaOH and optionally chelating and stabilization chemicals were prepared. OBA is added to the bleach solution in those experiments in which OBA is a component of the bleach composition to demonstrate the invention. The various bleach solutions (those with and without OBA) were well mixed with the starting pulp. The mixture was then sealed in a plastic bag and the sealed plastic bag placed into a temperature bath containing water, which was preset and controlled to a constant temperature target. The sealed plastic bag was kept in the bath for the predetermined time duration, after which the bag was opened and the pulp washed with distill/deionize water. The ISO brightness of the washed pulp was determined by the procedure of TAPPI T452 Test Method and the CIE Whiteness of the washed pulp was determined by the standard CEILAB coordinates.

The specific process conditions and the results of the evaluation are set forth in the following Table I and in FIGS. 1 through 18.

TABLE I Aspen BCTMP Ex H₂O₂ NaOH Na₂SiO₃ ¹DTPA MgSO₄ ²AP ³T ⁴C Time Initial Final Final Final Initial Initial No. (%) (%) (%) (%) (%) (#/ton) (#/ton) (%) hrs T ° C. pH pH ISO CIE ISO CIE C1 6 5 3 0.5 0.5 0 20 3 85 11.0 9.0 84.6 62.7 73.1 32.2 1A 6 5 3 0.5 0.5 5 20 3 85 11.0 9.3 89.9 93.4 73.1 32.2 2A 6 5 3 0.5 0.5 10 20 3 85 11.0 9.1 90.8 97.7 73.1 32.2 3A 6 5 3 0.5 0.5 20 20 3 85 11.1 8.9 92.4 105.1 73.1 32.2 C2 4 2.5 3 0.5 0 0 20 2.0 80 10.5 7.9 81.6 56.2 77.2 43.8 1B 4 2.5 3 0.5 0 5 20 2.0 80 10.4 8.0 85.2 75.9 77.2 43.8 2B 4 2.5 3 0.5 0 10 20 2.0 80 10.4 8.2 84.8 75.4 77.2 43.8 3B 4 2.5 3 0.5 0 20 20 2.0 80 10.4 7.8 87.0 87.2 77.2 43.8 C3 5 2.5 4 0.7 0 0 20 2.0 80 10.4 8.3 81.9 55.4 77.2 43.8 4B 5 2.5 4 0.7 0 5 20 2.0 80 10.4 8.2 85.8 77.5 77.2 43.8 5B 5 2.5 4 0.7 0 10 20 2.0 80 10.4 8.6 85.7 78.3 77.2 43.8 6B 5 2.5 4 0.7 0 20 20 2.0 80 10.4 8.1 88.9 95.5 77.2 43.8 C4 5 2.5 5 1 0 0 20 2.0 80 10.3 8.2 82.2 57.2 77.2 43.8 7B 5 2.5 5 1 0 5 20 2.0 80 10.5 8.4 85.5 75.2 77.2 43.8 8B 5 2.5 5 1 0 10 20 2.0 80 10.4 7.8 89.1 93.5 77.2 43.8 9B 5 2.5 5 1 0 20 20 2.0 80 10.5 8.5 89.4 98.0 77.2 43.8 C5 2 1.5 3 0.5 0 0 20 1.0 80 10.4 7.6 80.7 52.3 77.2 43.8 C6 4 2.5 3 0.5 0 0 20 1.0 80 10.5 7.8 83.0 57.9 77.2 43.8 C7 6 3.5 3 0.5 0 0 20 1.0 80 10.8 8.2 83.9 61.7 77.2 43.8 C8 2 1.5 3 0.5 0 0 20 3.0 80 10.4 7.1 80.6 51.5 77.2 43.8 C9 4 2.5 3 0.5 0 0 20 3.0 80 10.5 7.2 83.6 59.4 77.2 43.8 C10 6 3.5 3 0.5 0 0 20 3.0 80 10.8 7.8 84.7 64.3 77.2 43.8 C11 2 1.5 3 1 0 0 20 1.0 80 10.7 7.9 80.1 51.2 77.2 43.8 C12 4 2.5 3 1 0 0 20 1.0 80 10.6 7.7 82.9 57.7 77.2 43.8 C13 6 3.5 3 1 0 0 20 1.0 80 10.9 8.0 84.2 61.6 77.2 43.8 C14 2 1.5 3 1 0 0 20 3.0 80 10.7 7.3 79.9 50.6 77.2 43.8 C15 4 2.5 3 1 0 0 20 3.0 80 10.6 7.4 83.1 58.6 77.2 43.8 C16 6 3.5 3 1 0 0 20 3.0 80 10.9 7.5 85.0 63.4 77.2 43.8 10B 6 3.5 3 1 0 5 20 1.0 80 10.8 8.1 89.0 89.2 77.2 43.8 11B 6 3.5 3 1 0 10 20 1.0 80 10.7 8.1 88.6 90.0 77.2 43.8 12B 6 3.5 3 1 0 20 20 1.0 80 10.7 8.5 90.6 100.6 77.2 43.8 13B 6 3.5 3 1 0 5 20 3.0 80 10.8 7.8 89.6 90.4 77.2 43.8 14B 6 3.5 3 1 0 10 20 3.0 80 10.7 8.1 90.7 97.8 77.2 43.8 15B 6 3.5 3 1 0 20 20 3.0 80 10.7 7.9 92.2 104.5 77.2 43.8 C17 6 5 3 1 0 0 20 2.5 85 10.9 8.8 83.5 63.5 77.2 43.8 16B 6 5 3 1 0 5 20 2.5 85 11.0 8.8 90.1 98.4 77.2 43.8 17B 6 5 3 1 0 10 20 2.5 85 11.0 8.9 91.7 104.4 77.2 43.8 18B 6 5 3 1 0 20 20 2.5 85 11.0 9.0 93.2 112.1 77.2 43.8 C18 6 5 3 0.5 0.5 0 20 3.0 85 11.0 9.0 84.9 65.3 77.2 43.8 19B 6 5 3 0.5 0.5 5 20 3.0 85 11.0 9.1 91.2 99.9 77.2 43.8 20B 6 5 3 0.5 0.5 10 20 3.0 85 11.0 9.1 93.1 108.5 77.2 43.8 21B 6 5 3 0.5 0.5 20 20 3.0 85 11.0 9.2 94.0 113.8 77.2 43.8 C19 6 3 3 0.5 0.5 0 20 2 85 10.8 NM 84.4 61.6 77.2 43.8 22B 0 0 0 0 0 5 10 2 65 9.2 8.4 90.1 91.4 77.2 43.8 23B 0 0 0 0 0 10 10 2 65 9.2 NM 91.9 100.6 77.2 43.8 24B 0 0 0 0 0 20 10 2 65 9.2 NM 93.4 108.2 77.2 43.8 C20 0 0 0 0 0 0 5 .02 25 7.0 7.0 — — 77.2 43.8 C21 0 0 0 0 0 5 5 02 25 7.0 7.0 78.5 48.3 77.2 43.8 C22 0 0 0 0 0 10 5 02 25 7.0 7.0 78.6 48.3 77.2 43.8 C23 0 0 0 0 0 20 5 02 25 7.0 7.0 79.3 52.8 77.2 43.8 C24 0 0 0 0 0 40 5 02 25 7.0 7.0 80.2 57.6 77.2 43.8 C25 0 0 0 0 0 0 5 .02 25 7.0 7.0 — — 77.2 43.8 C26 0 0 0 0 0 5 5 02 25 7.0 7.0 80.1 57.9 77.2 43.8 C27 0 0 0 0 0 10 5 02 25 7.0 7.0 80.9 63.1 77.2 43.8 C28 0 0 0 0 0 20 5 02 25 7.0 7.0 81.8 68.5 77.2 43.8 C29 0 0 0 0 0 40 5 02 25 7.0 7.0 83 75 77.2 43.8 C30 2 1.25 3 1 0 20 2.0 80 10.8 9.5 84.3 66.6 82.4 57.1 1C 2 1.25 3 1 5 20 2.0 80 10.9 9.9 89.6 94.9 82.4 57.1 2C 2 1.25 3 1 10 20 2.0 80 11.0 9.3 91.3 105.6 82.4 57.1 3C 2 1.25 3 1 20 20 2.0 80 11.0 9.4 92.7 110.3 82.4 57.1 C31 4 2.5 3 1 0 20 2.0 80 10.8 9.5 84.7 76.1 82.4 57.1 4C 4 2.5 3 1 5 20 2.0 80 10.9 9.9 91.5 113.1 82.4 57.1 5C 4 2.5 3 1 10 20 2.0 80 11.0 9.3 94.2 113.9 82.4 57.1 6C 4 2.5 3 1 20 20 2.0 80 11.0 9.4 97.4 126.3 82.4 57.1 7C 5 2.5 3 1 20 20 1.0 80 10.5 10.1 92.7 111.4 82.4 57.1 8C 5 2.5 3 1 20 20 2.0 80 10.5 9.8 94.6 119.8 82.4 57.1 9C 5 2.5 3 1 20 20 4.0 80 10.5 9.5 95.6 123.2 82.4 57.1 10C 5 2.5 3 1 0 20 20 1 80 10.5 10.1 92.7 111.4 82.4 57.1 11C 5 2.5 3 1 0 20 20 2 80 10.5 9.8 94.6 119.8 82.4 57.1 12C 5 2.5 3 1 0 20 20 4 80 10.5 9.5 95.6 123.2 82.4 57.1 C32 6 5 3 0.5 0.5 0 20 3 85 11.5 10.1 86.4 74.7 82.4 57.1 13C 6 5 3 0.5 0.5 5 20 3 85 NM 10.0 92.8 113.1 82.4 57.1 14C 6 5 3 0.5 0.5 10 20 3 85 NM 10.1 94.9 119.4 82.4 57.1 15C 6 5 3 0.5 0.5 20 20 3 85 11.4 10.0 95.9 126.0 82.4 57.1 C33 0 0 0 0 0 0 5 .02 25 7.0 7.0 — — 82.4 57.1 C34 0 0 0 0 0 5 5 02 25 7.0 7.0 83.0 60.9 82.4 57.1 C35 0 0 0 0 0 10 5 02 25 7.0 7.0 83.9 64.1 82.4 57.1 C36 0 0 0 0 0 20 5 02 25 7.0 7.0 84.1 68.6 82.4 57.1 C37 0 0 0 0 0 40 5 02 25 7.0 7.0 84.2 67.6 82.4 57.1 C38 0 0 0 0 0 0 5 .02 25 7.0 7.0 — — 82.4 57.1 C39 0 0 0 0 0 5 5 02 25 7.0 7.0 85.2 71.4 82.4 57.1 C40 0 0 0 0 0 10 5 02 25 7.0 7.0 86.2 78.3 82.4 57.1 C41 0 0 0 0 0 20 5 02 25 7.0 7.0 87.2 83.9 82.4 57.1 C42 0 0 0 0 0 40 5 02 25 7.0 7.0 88.9 93 82.4 57.1 C43 0 0 0 0 20 10 1.5 72 10.5 NM 86.8 87.4 82.4 59.2 C44 0 0 5 0 20 10 1.5 72 10.5 NM 84.1 87.5 82.4 59.2 C45 0 0 0 1 20 10 1.5 72 10.5 NM 82.3 84.3 82.4 59.2 C46 0 0 0 0 20 10 2.0 72 10.5 NM 88.6 95.1 82.4 59.2 C47 0 0 0 0 20 12 2.0 65 7.4 NM 89.9 98.3 82.4 59.2 C48 0 0 0 0 20 12 4.0 65 7.4 NM 89.6 96.7 82.4 59.2 1D 1 0 0 0 20 12 2.0 65 6.9 6.6 90.6 98.8 82.4 59.2 2D 1 0 0 0.5 20 12 2.0 65 7.4 7.2 90.7 99.8 82.4 59.2 3D 1 0 0 0 20 12 4.0 65 6.9 6.7 90.8 99.3 82.4 59.2 4D 1 0 0 0.5 20 12 4.0 65 7.4 7.2 90.9 99.7 82.4 59.2 C49 2 1.5 3 0.5 0 0 20 1.0 80 10.4 7.6 80.7 52.3 77.2 43.8 C50 4 2.5 3 0.5 0 0 20 1.0 80 10.5 7.8 83.0 57.9 77.2 43.8 C51 6 3.5 3 0.5 0 0 20 1.0 80 10.8 8.2 83.9 61.7 77.2 43.8 77.2 43.8 C52 2 1.5 3 0.5 0 0 20 3.0 80 10.4 7.1 80.6 51.5 77.2 43.8 C53 4 2.5 3 0.5 0 0 20 3.0 80 10.5 7.2 83.6 59.4 77.2 43.8 C54 6 3.5 3 0.5 0 0 20 3.0 80 10.8 7.8 84.7 64.3 77.2 43.8 77.2 43.8 C55 2 1.5 3 1 0 0 20 1.0 80 10.7 7.9 80.1 51.2 77.2 43.8 C56 4 2.5 3 1 0 0 20 1.0 80 10.6 7.7 82.9 57.7 77.2 43.8 C57 6 3.5 3 1 0 0 20 1.0 80 10.9 8.0 84.2 61.6 77.2 43.8 77.2 43.8 C58 2 1.5 3 1 0 0 20 3.0 80 10.7 7.3 79.9 50.6 77.2 43.8 C59 4 2.5 3 1 0 0 20 3.0 80 10.6 7.4 83.1 58.6 77.2 43.8 C60 6 3.5 3 1 0 0 20 3.0 80 10.9 7.5 85.0 63.4 77.2 43.8

In Table I, “DTP” is diethylene triamine pentacetic acid, “AP” is Leucophor AP, “T” is Leucophor T-100, and “C” is pulp consistency.

EXAMPLES 1E TO 3G AND COMPARATIVE EXAMPLES C60 to C60

Using the procedure of Examples 1A to 10 D and Comparative Examples C1 to C34, a series of experiments were carried out to Spruce CTMP pulp is treated bleach chemical solutions containing the desired amounts of H₂O₂, NaOH and optionally OBA, chelating and stabilization chemicals. One purpose of these experiments is to demonstrate the effect of effect of treatment time, duration of the treatment, temperature, consistency and chemical additives (Leucophor AP, H₂O₂, Na₂SiO₃, DTPA) on the ISO brightness and the CIE Whiteness of the treated Spruce CTMP pulp.

The specific process conditions and the results of the evaluation are set forth in the following Table II.

TABLE II Spruce CTMP Example H₂O₂ NaOH Na₂SiO₃ DTPA Cons Time Temp Initial Final OBA Final Final Initial Initial No. (%) (%) (%) (%) (%) hrs ° C. pH pH (#/ton) CIE ISO ISO CIE C61 1 2.5 1 0 10 2 85 11.3 9.3 0 −15.6 56.6 58.2 3.5 C62 2 2.5 1 0 10 2 85 11.0 8.6 0 9.8 65.8 58.2. 3.5 C63 3 2.5 1 0 10 2 85 10.8 8.0 0 21.3 70.1 58.2 3.5 C64 4 2.5 3 0 12 2 80 10.9 10.4 0 41.4 77.3 70.1 21.3 C65 4 2.5 3 0.5 12 2 80 10.7 9.0 0 34.7 74.7 58.2 3.5 C66 4 2.5 3 0.5 20 2 80 11.0 10.3 0 49.6 79.7 74.7 34.7 C67 4 2.5 3 0.5 12 2 80 10.7 9.0 0 34.7 74.7 58.2 3.5 C68 0 0 0 0 10 2 65 7.4 10 44.7 74.9 74.7 34.7 C69 0 0 0 0 10 2 65 7.1 20 51.2 77.2 74.7 34.7 C70 0 0 0 0 10 2 65 7.0 30 54.7 77.5 74.7 34.7 C71 3 2.5 1 0 10 2 85 10.8 8.0 0 21.3 70.1 58.2 3.5 C72 4 2.5 3 0 12 2 80 10.9 10.4 0 41.4 77.3 70.1 21.3 C73 0 0 0 0 10 2 65 11.2 10.8 5 52.9 78.5 77.3 41.4 C74 0 0 0 0 10 2 65 11.2 10.7 10 68.4 81.6 77.3 41.4 C75 0 0 0 0 10 2 65 11.2 10.7 20 73.4 82.1 77.3 41.4 C76 4 2.5 3 0.5 12 2 80 10.7 9.0 0 34.7 74.7 58.2 3.5 C77 4 2.5 3 0.5 20 2 80 11.0 10.3 0 49.6 79.7 74.7 34.7 C78 0 0 0 0 10 2 65 7.5 10 60.9 80.0 79.7 49.6 C79 0 0 0 0 10 2 65 7.5 20 66.0 81.1 79.7 49.6 C80 0 0 0 0 10 2 65 7.3 30 70.8 82.0 79.7 49.6 C81 4 3 3 0.5 20 2 80 10.6 8.9 0 38.2 76.1 58.2 3.5 1E 4 3 3 0.5 20 2 80 10.8 8.8 10 60.0 79.6 76.1 38.2 2E 4 3 3 0.5 20 2 80 10.8 9.0 20 66.2 80.6 79.6 60.0 C82 3 2.5 1 0 10 2 85 10.8 8.0 0 21.3 70.1 58.2 3.5 C83 4 2.5 3 0.5 12 2 80 10.8 10.3 0 41.6 77.4 70.1 21.3 1F 4 2.5 3 0.5 12 2 80 10.8 10.2 5 59.3 80.0 70.1 21.3 2F 4 2.5 3 0.5 12 2 80 10.9 10.3 10 67.7 81.7 70.1 21.3 3F 4 2.5 3 0.5 12 2 80 10.8 10.3 20 75.8 82.8 70.1 21.3 C84 4 2.5 3 0.5 12 2 80 10.7 9.0 0 34.7 74.7 58.2 3.5 C85 4 2.5 3 0.5 20 2 80 11.0 10.3 0 49.6 79.7 74.7 34.7 1G 4 2.5 3 0.5 20 2 80 10.9 10.2 5 64.4 81.9 74.7 34.7 2G 4 2.5 3 0.5 20 2 80 11.0 10.3 10 70.1 83.3 74.7 34.7 3G 4 2.5 3 0.5 20 2 80 10.7 10.3 20 76.9 84.3 74.7 34.7

EXAMPLES 1H to 3H

Using the procedure of Examples 1A to 10D and Comparative Examples C1 to C34, a series of experiments were carried out to treat Aspen BCTMP pulp with bleach chemical solutions. The bleaching solution contained 6% H₂O₂, 5% NaOH, 3% Na₂SiO₃, 0.5% DTPA and 0.5% MgSO₄. The bleaching mixture was mixed with pulp at a consistency of 20% and bleach at a temperature of 85° C. for 2 hours at an initial pH of 10.8. The final ISO brightness was 84.4 and the final CIE whiteness was 61.6. After bleaching was completed, then OBA Leucophor AP was added to the mixture of pulp and spent bleaching chemicals and the consistency reduced to 10%. One purpose of these experiments is to demonstrate the effect on the ISO brightness and the CIE Whiteness of the treated Aspen BCTMP pulp when the pulp is treated with OBA in the presence of spent bleaching chemicals.

The specific process conditions and the results of the evaluation are set forth in the following Table III.

TABLE III Example OBA Time Initial Final Final Final No. (#/ton) hrs T ° C. pH pH ISO CIE 1H 5 2 65 9.2 8.4 90.1 91.4 2H 10 2 65 9.2 — 91.9 100.6 3H 20 2 65 9.2 — 93.4 108.2

EXAMPLE 1I

A series of experiments were conducted determine the relative to the cross sectional distribution of the optical brightener in the pulp of this invention and pulp treated with OBA using conventional processes. The pulp sample of this invention evaluated was that of Example 6C and one of the conventionally brightened pulps was that of Example C23. The other conventional pulp analyzed was similar to that of Example C23 except that it was treated at a consistency of 1%. In these experiments, a small specimen was cut from each handsheet and embedded in embedding medium. Cross sections were prepared and examined under an optical microscope using UV/Fluorescence illumination. Photomicrographs were taken at 216× and 432× using our Tectronic analog camera to show OBA distribution and intensity. The results are set for the in FIGS. 21 to 24. The photomicrographs of the sample of Example 6C are shown in FIGS. 19 and 22, the photomicrographs of the sample of Example C23 are shown in FIGS. 20 and 23, and the photomicrographs of the samples of the other conventionally brightened pulp are shown in FIGS. 21 and 24. The sample of Example 6C showed much stronger fluorescence signals than the other test samples.

EXAMPLE 2 Example 2a

In a first stage, a pulp containing a mixture of 50 wt % hardwood CTMP (freeness greater than 200; shive less than 0.2%) based upon the total dry weight of the fibers and 50 wt % bleached hardwood kraft (taken after a D1 or D2 bleaching stage) based upon the total dry weight of the fibers at a consistency of about 12% was contacted with 1.5 wt % H₂O₂, 0.25 wt % Optical Brightener Agent (disulfonated stilbene based OBA obtained from Clariant under the tradename Leucophor AP), 0.2 wt % DTPA, 0.2 wt % magnesium sulfate, 2 wt % sodium silicate, 1.2 wt % caustic (NaOH) for 2 hours at 80° C. (all wt % are based upon the dry weight of the pulp). The resultant pulp is then washed and subjected to a second stage in which the mixture is contacted with 4.0 wt % H₂O₂, 0.25 wt % Optical Brightener Agent (disulfonated stilbene based OBA obtained from Clariant under the tradename Leucophor AP), 0.2 wt % DTPA, 0.2 wt % magnesium sulfate, 2 wt % sodium silicate, 2 wt % caustic (NaOH) for about 5 hours at 80° C. (all wt % are based upon the dry weight of the pulp). The resultant pulp was washed and squeezed. The ISO brightness of the resultant pulp was 96 or an increase of at least 40 ISO points.

Example 2b

In a first and only stage, a pulp containing a mixture of 50 wt % softwood CTMP (freeness greater than 200; shive less than 0.2%) based upon the total dry weight of the fibers and 50 wt % bleached hardwood kraft (taken after a D1 or D2 bleaching stage) based upon the total dry weight of the fibers at a consistency of about 12% was contacted with 6 wt % H₂O₂, 0.5 wt % Optical Brightener Agent (disulfonated stilbene based OBA obtained from Clariant under the tradename Leucophor AP), 0.5 wt % DTPA, 0.5 wt % magnesium sulfate, 5 wt % sodium silicate, 5 wt % caustic (NaOH) for about 7 hours at 80° C. (all wt % are based upon the dry weight of the pulp). The resultant pulp is then washed and squeezed. The ISO brightness of the resultant pulp was about 90 to 91.

Example 2c

In a first stage, a pulp containing a mixture of 70 wt % hardwood CTMP (freeness greater than 200; shive less than 0.2%) based upon the total dry weight of the fibers and 30 wt % bleached softwood kraft (taken after a D1 or D2 bleaching stage in which chlorine based bleaching agents such as chlorine dioxide, elemental chlorine may be utilized) based upon the total dry weight of the fibers at a consistency of about 12% was contacted with 1.5 wt % H₂O₂, 0.25 wt % Optical Brightener Agent (disulfonated stilbene based OBA obtained from Clariant under the tradename Leucophor AP), 0.2 wt % DTPA, 0.2 wt % magnesium sulfate, 2 wt % sodium silicate, 1.2 wt % caustic (NaOH) for 2 hours at 80° C. (all wt % are based upon the dry weight of the pulp). The resultant pulp is then washed and subjected to a second stage in which the mixture is contacted with 4.0 wt % H₂O₂, 0.25 wt % Optical Brightener Agent (disulfonated stilbene based OBA obtained from Clariant under the tradename Leucophor AP), 0.2 wt % DTPA, 0.2 wt % magnesium sulfate, 2 wt % sodium silicate, 2 wt % caustic (NaOH) for about 5 hours at 80° C. (all wt % are based upon the dry weight of the pulp). The resultant pulp was washed and squeezed. The ISO brightness of the resultant pulp was 90 to 91.

For Examples 2 a-2 c above, any variance in the pulp mixture is acceptable so as to achieve the desired ISO brightness of the end product, especially those preferred above. Both the Kraft and the CTMP may be made from hardwood and/or softwood species.

As used throughout, ranges are used as a short hand for describing each and every value that is within the range, including all subranges therein.

Numerous modifications and variations on the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the accompanying claims, the invention may be practiced otherwise than as specifically described herein.

All of the references, as well as their cited references, cited herein are hereby incorporated by reference with respect to relative portions related to the subject matter of the present invention and all of its embodiments. 

1. An improved process for manufacturing brightened mechanical pulp comprising treating the pulp with one or more optical brightening agents in the presence of one or more bleaching agents, wherein the bleaching agents are selected from the group consisting of bleaching agents other than chlorine based bleaching agents.
 2. A process according to claim 1 wherein said pulp id treated in the presence of active bleaching agents.
 3. A process according to claim 1 wherein said pulp is treated in the presence of spent bleaching agents.
 4. A process according to claim 1 wherein said bleaching agent comprises peroxide.
 5. A bleached mechanical pulp having an ISO brightness equal to or greater than about 90 and pulp mixtures comprising such mechanical pulp.
 6. An improved process for forming bleached mechanical pulp of the type comprising: (a) a mechanical refining stage wherein wood chips are mechanically refined to form mechanical refined wood pulp; and (b) a bleaching stage wherein said mechanical refined wood pulp is bleached in one or more bleaching stages to form a bleached mechanical refined wood pulp; the improvement comprising bleaching the mechanical refined wood pulp with one or more bleaching agents in the presence of one or more optical brightening agent, said bleaching agents selected from the group consisting of oxidative bleaching agents other than chlorine based bleaching agents such as chlorine dioxide, elemental chlorine or a combination thereof, reductive bleaching agents or any combination of two or more thereof.
 7. An improved pulping and paper making process of the type comprising: (a) a mechanical refining stage wherein wood chips are mechanically refined to form mechanical refined wood pulp, (b) a bleaching stage wherein said mechanically refined wood pulp is bleached in one or more bleaching stages to form bleached mechanical refined aspen wood pulp, (c) a furnish forming stage wherein an aqueous paper making stock furnish comprising said bleached mechanical refined wood pulp is formed; (d) a furnish depositing stage wherein said furnish is deposited on a forming wire of a paper making machine to form a wet paper web; and (e) a wet paper web drying stage wherein said wet paper web to form a first dried paper web, the improvement comprising bleaching the mechanical refined wood pulp with one or more bleaching agents in the presence of one or more optical brightening agent, said bleaching agents selected from the group consisting of oxidative bleaching agents other than chlorine based bleaching agents such as chlorine dioxide, elemental chlorine or a combination thereof, reductive bleaching agents or any combination of two or more thereof.
 8. A paper or paper board web comprising bleached mechanical pulp having an ISO brightness equal to or greater than about
 90. 9. The paper or paper board web according to claim 8 having from 10 to 20% bulk enhancement.
 10. A process for manufacturing brightened pulp, comprising treating the pulp with one or more optical brightening agents in the presence of one or more bleaching agents, wherein the bleaching agents are selected from the group consisting of bleaching agents other than chlorine based bleaching agents.
 11. The process according to claim 10, wherein the pulp is a mixture of mechanical and chemical fibers.
 12. The process according to claim 11, wherein the mechanical fibers have a Canadian Standard Freeness of at least 200 csf and a shive content of not more than 0.5%.
 13. The process according to claim 12, wherein the mechanical fibers are CTMP.
 14. The process according to claim 13, further comprising pre-treating the chemical fibers with at least one bleaching stage in the presence of at least one chlorine based bleaching agent.
 15. The process according to claim 14, wherein the pulp comprises from 20 to 80 wt % of mechanical fibers and from 20 to 80 wt % to of chemical fibers based upon the total dry weight of the fibers.
 16. The process according to claims 15, wherein from 0.5 to 10 wt % of bleaching agent based upon the total dry weight of the pulp and from 0.1 to 2 wt % of optical brightener based upon the total dry weight of the pulp is used in the treatment of the pulp.
 17. The process according to claim 16, wherein said treating is performed in the presence of from 1.0 to 8.0 wt % of stabilizer based upon the total dry weight of the pulp.
 18. The process according to claim 17, wherein the treating is for a time period of from 0.5 to 10 hours at a temperature of from 25 to 120° C., at a fiber consistency of at least 10%.
 19. A mixture of mechanical and chemical fibers made from the process according to claim 18 and having an ISO brightness that is at least 90 ISO points.
 20. A paper or paperboard substrate, comprising the mixture of mechanical and chemical fibers according to claim 19 and having an ISO brightness that is at least 90 ISO points. 